Method and system for mounting a supplemental alternator to a vehicle

ABSTRACT

A mounting system for mounting a supplemental alternator, as well as methods of assembling the same, is provided. The mounting system includes a top mounting bracket that is configured to align with a top flange aperture of the additional alternator. The mounting system also includes a bottom mounting bracket having a bracket aperture that aligns with an aperture of an existing alternator mount and also having a flange aperture that aligns with the foot flange aperture of the additional alternator. The mounting system further includes a shaft that couples to the additional alternator.

CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY

This is a continuation application that claims priority benefit ofco-pending U.S. patent application Ser. No. 16/700,841, filed Dec. 2,2019, and entitled “Method And System For Mounting A SupplementalAlternator To A Vehicle,” which claims priority benefit of U.S.Provisional Patent Application No. 62/773,580, filed Nov. 30, 2018, andentitled “Method And System For Mounting A Supplemental Alternator To AVehicle,” all of which are hereby incorporated herein by reference inthe entirety.

TECHNICAL FIELD

The present invention relates to systems and methods of mounting asupplemental alternator to a vehicle. Much of the discussion thatfollows will relate to mounting the additional alternator alongside anexisting alternator within an engine of an ATV (all-terrain vehicle) orUTV (utility vehicle). However, it is to be appreciated that systems andmethods of the present invention could have uses in other vehicles andtherefore the invention is not restricted to just an ATV or UTV.

BACKGROUND OF INVENTION

Portable generators are often used in remote locations when electricalpower is unavailable (“off grid”). Most portable generators arestandalone generators that are stowed during transportation, removedfrom storage when needed, and then powered up. Portable generators cancreate a number of problems. For instance, portable generators can takeup valuable storage capacity. This is a significant problem for certaintypes of vehicles that have limited storage space, such as in ATVs(all-terrain vehicles) or UTVs (utility vehicles). In addition,standalone generators may create unwanted weight. As portable generatorsusually run on independent combustion engines, the combustion engine mayintroduce additional weight and additional fuel. This is unsatisfactorywhen an ATV or UTV has a limited amount of weight it can handle.

To further complicate matters, standalone generators must be removedfrom storage and started. This is a time intensive task as it mayinvolve removing the standalone generator from storage and placing it onthe ground. Additionally, removing the standalone generator from storageis cumbersome as the standalone generator may be heavy, introducingopportunities for mishandling (e.g., dropping) the generator. Inaddition to being cumbersome, time may be wasted in removing thestandalone generator from storage and then starting it. As such,standalone generators that must be stowed typically do not provideon-demand electrical power while the vehicle is moving or immediatelyafter the vehicle has been stopped. This is an unsatisfactory solutionsince certain scenarios require electrical power in on-demand situationswhile the vehicle is in motion or shortly thereafter. For instance, manymilitary UTVs may require on-demand electrical power to operatecounter-measure systems, such as, actively jamming a detonation signalfor an improvised explosive device (IED).

There are also problems associated with in-engine mounted generators.For instance, while a vehicle's existing alternator could potentially beused to provide power to auxiliary electrical systems independent of thevehicle, these existing alternators generally cannot meet the demandsrequired by certain auxiliary electrical systems. This is because manyvehicles rely on a 12 volt alternator, which cannot produce enough powerrequired for auxiliary electrical systems. This limits the auxiliaryelectrical systems available for use with the vehicle.

SUMMARY

This summary is intended to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription section of this disclosure. This summary is not intended toidentify key or essential features of the claimed subject matter, and itis not intended to be used as an aid in isolation for determining thescope of the claimed subject matter.

In brief, and at a high level, this disclosure describes mounting anadditional alternator within an engine compartment while reducing thetime and effort to modify other components within the enginecompartment. More specifically, the present disclosure describesmethods, apparatuses, and systems for mounting an additional in-enginealternator using offset brackets and an extended shaft. The additionalalternator can then be used to supplement the electrical power suppliedby the existing vehicle's alternator. In other words, while the existingvehicle alternator typically generates electrical power for thevehicle's electrical system, the additional alternator may generateelectrical power to power non-vehicle accessories. Additionally, boththe existing vehicle alternator and the additional mounted alternatorcan be driven by the vehicle's crankshaft. For example, a crankshaft maydrive both the existing vehicle alternator (e.g., a 12V alternator) andthe additional alternator (e.g., a 24V alternator) through one or morebelts.

In one embodiment hereof, a mounting system for mounting an additionalalternator in combination with an existing alternator is provided. Themounting system includes a top bracket coupled with a top flange of theadditional alternator and a bottom bracket coupled with a bottom flangeof the additional alternator. A shaft is coupled to and extends from theadditional alternator. A pulley is attached to the shaft adjacent adistal end.

In another embodiment hereof, a method for mounting an additionalalternator to a vehicle having an existing alternator. The methodinclude securing a top bracket to an existing engine component andsecuring a bottom bracket to an alternator mount supporting the existingalternator. The method further includes mounting the additionalalternator alongside the existing alternator using the top and bottombrackets.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter disclosed herein is described in detail withreference to the attached drawing figures, which are intended toillustrate non-limiting examples of the disclosed subject matter relatedto supplemental alternators, in which like numerals refer to likeelements, wherein:

FIG. 1 is a perspective view of a mounting system in accordance withsome embodiments of the present invention;

FIGS. 2A-B are rear and side elevation views, respectively, inaccordance with some embodiments of the present invention;

FIG. 3 is a perspective view of an additional alternator mounted to anexisting alternator mounting bracket in accordance with some embodimentsof the present invention;

FIG. 4A is a front perspective view of an existing alternator and anexisting mounting system in accordance with some embodiments of thepresent invention;

FIG. 4B is a front perspective view of an additional alternator mountedto an existing alternator mounting system in accordance with someembodiments of the present invention;

FIG. 5A is a rear perspective view of an existing alternator and anexisting mounting system in accordance with some embodiments of thepresent invention;

FIG. 5B is a rear perspective view of an additional alternator mountedto an existing alternator mounting system in accordance with someembodiments of the present invention;

FIG. 6A is a front perspective view of a shaft in accordance with someembodiments of the present invention;

FIG. 6B is a cross-sectional view of the shaft of FIG. 6A taken in thedirection of line B-B in accordance with some embodiments of the presentinvention;

FIG. 7 is a cross-sectional view of the shaft of FIG. 6A in a mountedposition to the crankshaft of an additional alternator in accordancewith some embodiments of the present invention;

FIG. 8 is a side elevation view of the shaft of FIG. 6A with a pulleythereon in accordance with some embodiments of the present invention;

FIG. 9 is a flow diagram showing a method for retrofitting an enginewith an additional alternator in accordance with some embodiments of thepresent invention;

FIG. 10 is a front perspective view of an additional alternator mountedto an existing alternator mounting bracket in accordance with alternateembodiments of the present invention;

FIG. 11 is a rear perspective view of the additional alternator mountedto an existing alternator mounting bracket of FIG. 10; and

FIGS. 12A-B are each side elevation views of a fan plate before andafter modification, respectively, in accordance with some embodiments ofthe present invention.

DETAILED DESCRIPTION

The subject matter of the invention is described herein to meetstatutory requirements. However, this description is not intended tolimit the scope of the invention. Rather, the claimed subject matter maybe embodied in other ways, to include different steps, combinations ofsteps, features, and/or combinations of features, similar to thosedescribed in this disclosure, and in conjunction with other present orfuture technologies. Moreover, although the terms “step” and/or “block”may be used herein to identify different elements of methods employed,the terms should not be interpreted as implying any particular orderamong or between various steps or blocks except when the order isexplicitly described and required.

At a high level, embodiments described herein relate to retrofitting avehicle with an additional alternator. The additional alternator can bemounted in combination with an existing vehicle alternator, whichtypically generates electrical power for vehicle's electrical system.The additional alternator can generate additional electrical power thatis needed beyond the vehicle's electrical system.

The additional alternator can be mounted to an existing alternator mountthrough one or more brackets. The one or more brackets can be an offsetbracket that is secured to the existing holes or fasteners utilized bythe vehicle's existing alternator or other existing engine components.The offset bracket can offset the additional alternator to the rear ofthe existing vehicle alternator or the crankshaft pulley of thecrankshaft. The one or more brackets may have one or more bracketapertures that align with preexisting apertures in the existingalternator mount or other existing engine components. Accordingly, theoffset brackets can utilize fasteners that secure the existingalternator to the existing mount. Additionally, the offset brackets canutilize fasteners that already exist within other portions of the enginecompartment. When the additional alternator is mounted, a pulley of theadditional alternator can be aligned with a vehicle's crankshaft pulleythrough an extension shaft so that the vehicle's crankshaft pulley candrive the additional alternator. In some aspects, the additionalalternator pulley can also be aligned with a pulley of the existingalternator such that both alternators are driven by the vehicle'scrankshaft utilizing a common belt.

The extension shaft can be coupled to the additional alternator to bringthe additional alternator pulley into the same plane as the vehicle'scrankshaft pulley or the existing alternator pulley. Based on itsdimensions and material, the extension shaft is capable of withstandingthe torque that is created based on offsetting the additionalalternator. In some aspects, the extension shaft is supported by abearing to further withstand the torque. One or more belts can beutilized so that a crankshaft pulley attached to the vehicle's internalcombustion engine drives both the additional alternator and the existingalternator. In some aspects, a single belt can drive both alternators.

FIG. 1 is a perspective view of a mounting system 100 for an additionalalternator 102 according to an embodiment of the present invention. Ingeneral, the mounting system 100 can be used to retrofit a vehicle withthe additional alternator 102. The mounting system 100 may allow theadditional alternator 102 to be mounted within an engine compartment ofthe vehicle. The vehicle can thus have dual alternators that can providepower to both the vehicle's electrical system and the auxiliaryelectrical system. In some aspects, the dual alternators mayindependently power each respective electrical system. For example, anexisting alternator can power a vehicle's electrical system (charge thevehicle battery, provide power to the headlights, etc.), while theadditional alternator 102 can provide power to electrical systems thatare independent of the vehicle's electrical system.

In some aspects, the electrical power output of the alternators varies.For example, the existing alternator can be a 12V DC alternator thatprovides the necessary electrical power to the vehicle's electricalsystem. The additional alternator 102 can be a 24V DC alternator thatprovides the necessary electrical power to a secondary electrical systemrequiring a greater electrical load than the vehicle's electrical system(e.g., non-vehicle or auxiliary electrical systems).

As described, the additional alternator 102 may be mounted within theengine compartment 302 of a vehicle, as shown in FIG. 3. The additionalalternator 102 and the existing alternator 310 can share a commonalternator mount (sometimes referred to herein as the existingalternator mount). For example, as shown in FIG. 3, the additionalalternator 102 can be mounted to an existing alternator mount that isused to mount the existing alternator 310. To facilitate a quickerinstallation, one or more brackets may be configured to mount theadditional alternator 102 to the existing alternator mounting bracket.

The mounting system 100 may comprise an extension shaft or shaft 140having a first or proximal end 142 and a second or distal end 144. Asillustrated in FIG. 1, the first end 142 of the shaft 140 can be coupledto a shaft 104 (FIG. 7) of the additional alternator 102 while thesecond end 144 can be coupled to a pulley 810 (FIG. 8). The shaft 140may be adapted to fit, mate, or otherwise couple with the shaft of theadditional alternator 102 (e.g. through a “slip fit”). The shaft 140 canthen be secured to the additional alternator 102 using one or moreextension shaft fasteners. In some aspects, the shaft 140 may beconfigured to slip over the shaft of the additional alternator and heldin place by a key by one or more set screws. As discussed in greaterdetail below, the shaft 140 may be an extended shaft that brings thepulley 810 of the additional alternator 102 into alignment (e.g., withinthe same plane) with the existing alternator's pulley and/or thevehicle's crankshaft pulley. In some aspects, the shaft 140 creates agreater distance between the additional alternator pulley 810 and theface of the additional alternator 102 than the distance between a faceof the existing alternator and its pulley.

The mounting system 100 may further comprise one or more belts (notshown). Utilizing the one or more belts, the vehicle's crankshaft pulleycan drive both the existing alternator 310 and the additional alternator102. Typically, the vehicle's crankshaft pulley drives a pulley of thevehicle's existing alternator. When mounted, the additional alternator102 can also be driven by the vehicle's crankshaft pulley by one or morebelts, either in series or independently with the existing alternator.For instance, in various aspects, a single belt simultaneously drivesboth the additional alternator 102 and the existing alternator 310. Asdiscussed below, the pulley of the additional alternator 102 may bealigned with the pulley of the existing alternator 310 such that asingle belt drives both alternators. The single belt can thus be longerthan the existing belt so as to connect both the additional alternator102 and the existing alternator 310 in series.

In some aspects, two belts are utilized to drive both alternatorpulleys. A first belt can independently drive a pulley of the additionalalternator 102 while a second belt can independently drive a pulley ofthe existing alternator 310. In other words, the additional alternator102 and the existing alternator 310 can be independently driven by thecrankshaft through separate belts.

While not shown, the mounting system 100 can further comprise aprotective guard. The protective guard can replace an existingprotective guard to shield the pulley of the additional alternator 102and the belt driving the additional alternator. One such example is thebelt guard 1146 of FIG. 10.

As noted above, the mounting system 100 may comprise one or morebrackets. For instance, the mounting system 100 may comprise a topbracket 110, a bottom bracket 120, or a combination thereof (as shown inFIG. 1). In general, the brackets can offset the additional alternator102 from the existing alternator 310 such that a front face of theadditional alternator 102 is positioned behind (or to the rear of) afront face of existing alternator 310. Utilizing offset brackets canallow an additional alternator to be mounted in an engine withoutsignificant modifications to other components of the engine.

The mounting system 100 can utilize existing holes in an existingalternator mount through one or more bracket apertures. For instance,the one or more bracket apertures in the top bracket 110 and the bottombracket 120 can be adapted to align with one or more existing aperturesin the alternator mount. As the brackets of the mounting system 100 canutilize existing holes in the alternator mount, the one or more bracketapertures can remove any need for additional drilling during theinstallation of the additional alternator 102. Accordingly, the one ormore bracket apertures increase the efficiency and safety of installingthe additional alternator 102.

As illustrated in FIG. 1, the top bracket 110 may comprise a first wall112 and a second wall 114. The first wall 112 and the second wall 114can be separated by a third wall 116 extending there between. In someaspects, the first wall 112, the second wall 114, and the third wall 116form a Z-bracket. While not necessary, the top bracket 110 can be aunitary structure. The first wall 112 may comprise a bracket aperture118 (also referred to as first wall aperture). The bracket aperture 118may be located on the first wall 112 such that it may be aligned with anaperture (also referred to as an existing aperture) in an existingalternator mount when the top bracket is secured to the existingalternator mount. For instance, as shown in FIGS. 4A-B, the bracketaperture 118 of the top bracket 110 can be aligned with an elongatedslot 410 in a first member 420 of an existing alternator mount. Afastener (e.g., a bolt, screw, or pin) can then secure the first wall112 to the first member 420 of the existing alternator mount byextending through both the elongated slot 410 and the bracket aperture118. It should be appreciated that, in some aspects, the fastener may bea common fastener 412 that secures both the top bracket 110 and theexisting alternator 310 to the first member 420 of the existingalternator mount.

Returning to FIG. 1, the additional alternator 102 can be mounted to thesecond wall 114 of the top bracket 110. For instance, the additionalalternator 102 may comprise a top flange 150 having a flange aperture152 that is alignable with a mounting aperture 122 in the second wall114. In some aspects, the mounting aperture 122 in the second wall 114can be an elongated slot having an arc. As such, the additionalalternator 102 can be rotatably adjusted with respect to the top bracket110.

As noted, the mounting system 100 may comprise a bottom bracket 120. Theadditional alternator 102 can be coupled to the existing alternatormount through the bottom bracket 120. While not necessary, the bottombracket 120 may be a unitary structure. In the illustrated embodiment,the bottom bracket is formed from two pieces that have been coupledtogether to act as one. The bottom bracket 120 may comprise a first wall124 that can be secured to the existing alternator mount. For example,as shown in FIG. 5A, the first wall 124 can be secured to a secondmember 514 of an existing mount. The bottom bracket 120 may comprise oneor more bracket apertures (e.g., apertures 126, 128) positioned on thefirst wall 124 such that they align with one or more existing aperturesin the second member 514 when the bottom bracket 120 is secured to theexisting alternator mount. In some aspects, the first wall 124 can besecured to the second member 514 of the existing alternator mountutilizing one or more fasteners.

As shown in FIGS. 5A-5B, the one or more fasteners (bolt, screw, pin,etc.) utilized to secure the bottom bracket 120 to the existingalternator mount may further secure the existing alternator 310 to theexisting alternator mount. In other words, the bottom bracket 120 of theadditional alternator 102 can share a common fastener with the existingalternator 310. For instance, as shown in FIGS. 5A-B, one or morefasteners 510, 512 can be used to mount the first wall 124 of the bottombracket 120 to the second member 514 of the existing alternator mount.The one or more fasteners 510, 512 can further secure the existingalternator 310 to the existing alternator mount, as shown in FIG. 4A.

The additional alternator 102 can be mounted to the existing thealternator mount through the bottom bracket 120. The additionalalternator 102 can be mounted to the bottom bracket 120 through one ormore fasteners that secure the additional alternator 102 to the bottombracket 120. In various aspects, the one or more fasteners can securethe additional alternator 102 to the bottom bracket 120 utilizing one ormore mounting flanges of the bottom bracket 120. For instance, the oneor more mounting flanges of the bottom bracket 120 can be secured to oneor more foot flanges of the additional alternator 102. As shown in FIG.1, the one or more mounting flanges 130, 132 of the bottom bracket 120can be spaced apart to engage corresponding foot flanges 136, 134,respectively, of the additional alternator 102. The mounting flanges130, 132 can be aligned with the two foot flanges 136, 134 such that theapertures of each are aligned. In other words, an aperture in each ofthe one or more mounting flanges 130, 132 can be aligned with anaperture in each of the foot flanges 136, 134. One or more fasteners(e.g., bolt, screw, and pin) may then be inserted through the aperturesof the corresponding mounting flanges and secure the additionalalternator 102 to the bottom bracket 120.

In some aspects, the mounting system may further comprise a shaft 140.The shaft 140 can be a cylindrical member extending from a first end toa second end. As illustrated in FIG. 1, the shaft 140 can be attached tothe additional alternator 102 by any known means (welding, screwthreads, pins, latch, etc.). The first or proximal end 142 may bepositioned near the face of the additional alternator 102. The shaft 140can also be coupled to a pulley (e.g., pulley 810 as shown in FIG. 8),such as at or adjacent the second or distal end 144. In a mountedposition, the shaft can extend perpendicular to the first and secondwalls 112, 114 of the top bracket 110. Additionally, the shaft 140 canextend parallel to the third wall 116 of the top bracket 110.

Further, in various aspects, the shaft 140 may comprise a plurality ofconcentric cylindrical portions having varying diameters. For example,as shown in FIG. 1, the shaft 140 may comprise a base portion 146 havinga greater diameter than a diameter of an extended portion 148. The baseportion 146 can be a greater diameter to allow it to slip over a shaftof the additional alternator 102, which is concealed in FIG. 1 by theshaft 140. The extended portion 148 can generally be defined as aportion of the shaft 140 that extends beyond the shaft of the additionalalternator 102.

In some aspects, the shaft 140 can be designed to account for the momentcreated by the belt that drives the additional alternator pulley at thesecond end 144. As described above, the additional alternator 102 can beoffset from the existing alternator 310 using one or more brackets.Because the existing alternator 310 is offset, a belt driving the pulleyat the second end 144 of the shaft 140 can create a side load thatcauses the shaft 140 to bend. In other words, because the shaft 140extends the shaft of the additional alternator 102, the additionalalternator pulley will be further away from the face of the additionalalternator 102. This may cause a greater side load on the extendedportion 148 at the second end 144 of the shaft 140, thereby introducinga greater moment than what is otherwise experienced by a non-extendedalternator shaft. In some aspects, to account for the greater moment,the base portion 146 and the extended portion 148 may have substantiallysimilar outer diameters or may have different ratios of length, as shownin FIGS. 6A-6B.

With reference to FIGS. 6A-7, the proximal end 142 of the shaft 140 maycomprise a bore 610 to receive the shaft 104 of the additionalalternator 102. Generally, the dimensions of the bore 610 (e.g.,diameter, depth, width, or height) allow the shaft 140 to fit over theshaft 104 of the additional alternator 102. The bore 610 can extendlengthwise along a central longitudinal axis of the shaft 140 (i.e., theaxis extending from the proximal end 142 to the distal end 144).Additionally, the dimensions of the bore 610 are such that they allowthe shaft 140 to be supported by the additional alternator 102 (e.g., bythe proximal end 142 coming into contact with a surface of a fan plate602 of the additional alternator 102). For example, the dimensions ofthe bore 610 can allow the shaft 140 to receive a portion of thealternator shaft 104 that extends beyond the fan plate 602 of theadditional alternator 102 such that the proximal end 142 of the shaft140 is reinforced by the additional alternator 102. In some aspects, theproximal end 142 is reinforced by directly contacting the outer surfaceof the fan plate 602 of the additional alternator 102. In some aspects,the proximal end 142 does not directly contact the surface, but isotherwise reinforced by the fan plate 602 via one or more intermediatelayers between the proximal end 142 and the outer surface of the fanplate 602 of the additional alternator 102. This can be advantageousbecause, in exemplary aspects, the shaft 140 can extend the pulleyfurther away from the face of the additional alternator 102. Extendingthe pulley creates a greater risk that the shaft 140 becomes unsecuredor off-balanced due to the greater moment created by a larger distancebetween the pulley 810 and the face of the additional alternator 102than would normally occur without use of the shaft 140. As such, whenthe shaft 140 is rotating, especially at high speeds, it is likely torattle or wobble. However, by including internal threads in the bore 610and external threads on an outer portion of the shaft 104 of theadditional alternator 102, a mechanical force may be applied between theproximal end 142 of the shaft 140 and a the outer surface of the fanplate 602 to eliminate any gap there between and to cause the shaft 140and the fan plate 602 to act and function as one piece, thereby greatlyreducing or eliminating possible rattling and wobbling.

In some embodiments, the bore 610 can include two concentric chambers toreceive the additional alternator shaft. As shown in FIG. 7, the bore610 may include an outer chamber 612 and an inner chamber 614. The outerchamber 612 can extend from the opening in the proximal end 142 of theshaft 140 and along the longitudinal axis of the shaft. In some aspects,the outer chamber 612 transitions to the inner chamber 614, whichengages or mates to the additional alternator shaft 104. As describedbelow, the inner chamber 614 can include a mating mechanism that engagesthe additional alternator shaft. In some embodiments, the outer chamber612 and the inner chamber 164 are cylindrical chambers. The outerchamber 612 can have a larger diameter with respect to the diameter ofthe inner chamber 614. In addition, the diameter of the outer chamber612 is larger than a diameter of the drive shaft 104 of the additionalalternator 102.

In some embodiments, the inner chamber 614 engages a portion of thealternator shaft by way of a mating mechanism. The mating mechanism canensure that the proximal end 142 of the shaft 140 is continuallyreinforced by the outer surface of the fan plate 602 of the additionalalternator 102 (e.g., by coming into contact with the fan plate 602 ofthe additional alternator 102). In some aspects, the inner chamber 614can include a screw thread 616 that mates with a screw thread of theshaft 104. The orientation of the screw thread 616 can be such that theshaft 140 will tighten on the shaft 104 of the additional alternator 102as the pulley 810 of the shaft 104 is being rotated by a belt. In otherwords, while the vehicle's engine is running and the belt is causing theshaft 140 to rotate, the orientation of the screw thread 616 will causethe shaft 140 to tighten with respect to the alternator shaft 104. Itshould be appreciated that as the shaft 140 is tightened, the proximalend 142 of the shaft 140 is forced toward the additional alternator 102.This can result in causing the proximal end 142 of the shaft 140 toclamp down against the outer surface of the fan plate 602 of theadditional alternator 102.

In some embodiments, to account for the greater side load, the shaft 140may be reinforced by a bearing, such as the bearing support system 1128as described in reference to FIG. 10. For example, the base portion 146or extended portion 148 of the shaft 140 may extend through an openingin a support bearing. The support bearing allows the shaft 140 to rotatewhile ensuring that the extended portion 148 of the shaft 140 does notbend or break due to the force created by a belt driving the pulley ofthe shaft 140.

As described herein, in various aspects, the additional alternator 102can be offset from the existing alternator 310. By offsetting theadditional alternator 102, it may allow the additional alternator 102 tobe mounted within the engine compartment 302. Additionally, offsettingthe additional alternator 102 may allow it to be mounted utilizingapertures in the existing alternator mount. This may reduce theinstallation time since it would not require further drilling. As shownin FIGS. 2B, 3, and 5B, the additional alternator 102 can be offset fromthe existing alternator 310. For example, the face of the additionalalternator 102 may be offset from the face of the existing alternator.Said differently, the solenoid of the additional alternator 102 can beoffset from the solenoid of the existing alternator 310. The mountingsystem 100 can facilitate offsetting the additional alternator 102 inone or more of the x-axis, y-axis, and z-axis. As used herein, thex-axis illustrates a lateral direction, the y-axis illustrates avertical direction, and the z-axis illustrates a longitudinal direction.

Turning now to FIG. 2B, in some aspects, the shaft 140 can extend fromthe additional alternator 102 beyond the top bracket 110 and bottombracket 120. Specifically, the shaft 140 can extend from a first end 142that is secured to a shaft of the additional alternator 102 and extendthrough the second end 144. When the additional alternator 102 ismounted in an offset position, the second end 144 of the shaft 140 canextend beyond the first wall 112 of the top bracket 110 (in addition tothe second and third walls 114, 116). Additionally, the second end 144of the shaft 140 can extend beyond the first wall 124 of the bottombracket 120. As such, the shaft 140 can extend the shaft 104 of theadditional alternator 102 to bring the pulley 810 within the same planeas the crankshaft pulley or the pulley of the existing alternator 310.

Turning now to FIG. 8, an exemplary side elevation view of the shaft 140and the pulley 810 is depicted in accordance with some embodiments ofthe present invention. The shaft 140 may be configured to secure orcouple the pulley 810 to the extended portion 148 adjacent the distalend 144. For example, the extended portion 148 of the shaft 140 can havea diameter that allows the shaft 140 to extend from a first side of thepulley 810, through an opening in the pulley 810, and beyond a secondside of the pulley 810. The portion of the extended portion 148extending beyond the second side of the pulley 810 adjacent the distalend 144 can include a screw thread that mates with a nut 830. As such,the nut 830 can be mated with the portion of the extended portion 148extending beyond the second side of the pulley 810, thereby securing thepulley 810 to the shaft 140.

In the embodiment illustrated in FIGS. 6A-8, the transition from thelarger diameter base portion 146 to the smaller diameter extendedportion 148 defines a stop collar 820 that helps set the lateralposition of the pulley 810 on the shaft 140. In particular, the collar820 orients the pulley 810 in a predefined position that allows thepulley 810 to be aligned with the pulley of the crankshaft or existingalternator. The collar 820 can be advantageous as it may increase thesafety of the installation of additional alternator 102. For instance,the collar 820 can eliminate the potential of human error in misaligningthe pulley 810 with the crankshaft pulley or the pulley of the existingalternator. In some aspects, the collar 820 may be a unitary structurewith the shaft 140. In some aspects, the collar 820 may be joined,coupled, or otherwise mated to the shaft 140.

FIG. 9 is a flow diagram showing a method 900 for retrofitting an enginewith an additional alternator in accordance with some embodiments of thepresent invention. At step 910, a top bracket is secured to an existingalternator mount. As described herein, in various aspects, the firstwall 112 of the top bracket 110 can be secured to the first member 420of the existing alternator mount. For instance, a bracket aperture 118in the first wall 112 of the top bracket 110 can be aligned with anexisting aperture (e.g., the elongated slot 410) in the first member 420of the existing alternator mount. A fastener can then be insertedthrough both the first wall 112 of the top bracket 110 and the firstmember 420 of the existing alternator mount. In some aspects, thefastener can also be utilized to secure the existing alternator 310 tothe first member 420 of the existing alternator mount. As such, the topbracket 110 and the existing alternator 310 may share a common fastenerwhile being secured to the first member 420.

At step 920, a bottom bracket can be secured to the existing alternatormount. For instance, in some aspects, the first wall 124 of the bottombracket 120 may be secured to the second member 514 of the existingalternator mount. In particular, one or more bracket apertures 126, 128in the first wall 124 of the bottom bracket 120 may be aligned with oneor more existing apertures in the second member 514 of the existingalternator mount. One or more fasteners (e.g., fasteners 510, 512) maythen be inserted through both the one or more bracket apertures 126, 128and the one or more existing apertures in the second member 514 of theexisting alternator mount. In some aspects, the one or more fastenersmay further secure the existing alternator 310 to the second member 514.As such, the bottom bracket 120 and the existing alternator 310 mayshare one or more common fasteners while being secured to the secondmember 514.

At step 930, a shaft (e.g., shaft 140) can be secured to an additionalalternator 102. As described, the shaft 140 generally has a first end142 and second end 144. The shaft 140 can be attached to the additionalalternator 102 at the first end 142 by any means known in the art, suchas through welding. The shaft 140 can be attached such that it drives arotor within the additional alternator 102. For example, the shaft 140may be attached to a rotor shaft that drives the rotor within theadditional alternator 102. As described herein, the shaft 140 may be anextended shaft that extends beyond the flanges of either the top orbottom mounting bracket 110, 120. In various aspects, the shaft 140 mayhave a greater diameter at the first end 142 than its diameter at thesecond end 144.

At step 940, the additional alternator 102 may be mounted to theexisting alternator mount via at least one of the top and bottombrackets 110, 120. As described above, the additional alternator 102 maybe secured to the top bracket 110 or bottom bracket 120, or acombination thereof. For instance, the top flange 150 of the additionalalternator 102 may comprise a flange aperture 152. During theinstallation of the additional alternator 102, the flange aperture 152of the top flange 150 can be aligned with the mounting aperture 122 inthe second wall 114 of the top bracket 110. A fastener can then beinserted through the flange aperture 152 of the top flange 150 and themounting aperture 122 in the second wall 114 and secure the additionalalternator 102 to the top bracket 110. As described in step 910, the topbracket 110 may be secured to the existing alternator mount.Accordingly, the additional alternator 102 may be mounted to theexisting alternator mount via the top bracket 110.

As mentioned, the additional alternator 102 may be mounted to theexisting alternator mount via the bottom bracket 120. For example, oneor more foot flanges (e.g., foot flanges 134, 136) of the additionalalternator 102 may each comprise a foot aperture. During theinstallation of the additional alternator 102, the foot aperture of eachfoot flange can be aligned with a mounting apertures in the one or moremounting flanges 130, 132 of the bottom bracket 120. A fastener can thenbe inserted through the foot aperture of the foot flange and theaperture in the mounting flange, thereby securing the additionalalternator 102 to the bottom bracket 120. As described in step 920, thebottom bracket 120 may be secured to the existing alternator mount.Accordingly, the additional alternator 102 may be mounted to theexisting alternator mount via the bottom bracket 120.

FIGS. 10-11 are front and rear perspective views, respectively, of amounting system 1000 for the additional alternator 102 in accordancewith an alternate embodiment of the present invention. The mountingsystem 1000 is similar the mounting system 100 of FIG. 1. For instance,the mounting system 1000 includes the shaft 140 and the bottom bracket120. As the shaft 140 and the bottom bracket 120 have been described ingreater detail above, they will not be described in detail here.Additionally, similar to the mounting system 100, mounting system 1000may offset the additional alternator 102 laterally, longitudinally, andvertically from an existing alternator, such as alternator 310. Forinstance, the additional alternator 102 may be offset laterally alongthe x-axis, vertically along the y-axis, and longitudinally along thez-axis from an existing alternator.

The mounting system 1000 includes a top bracket 1110. The top bracket1110 includes a wall 1114 that extends from a first end 1116 to a secondend 1118. The top bracket 1110 may be mounted to the additionalalternator 102 at the first end 1116. For example, the wall may have amounting aperture 1122 positioned at the first end 1116. The additionalalternator 102 may be mounted to the top bracket 1110 through a fastener(e.g., a bolt, screw, or pin) that is inserted through the mountingaperture 1122 and into the flange aperture 152.

In some aspects, the mounting aperture 1122 can be an elongated slothaving an arc. As such, the additional alternator 102 can be rotatablyadjusted with respect to the top bracket 1110. The elongated slot mayallow for a tensioning of one or more belts during installation of theadditional alternator 102. As the top flange 150 travels along theelongated slot, the tension in one or more belts may be decreased orincreased depending on the direction the top flange travels.

In some aspects, the second end 1118 of the top bracket 1110 is coupled(directly or indirectly) to an existing component of the engine. Asillustrated, the second end 1118 is coupled to a mounting post 1120. Thetop bracket 1110 is coupled to the mounting post 1120 via one or morefasteners (e.g., a bolt, screw, or pin). The mounting post 1120 includesa flange 1124 that can be mounted to any existing component of theengine compartment such that the additional alternator 102 is supported.For example, the flange 1124 includes an aperture(s) 1126 that alignswith existing mounting apertures that already exist in the enginecompartment. In some aspects, the aperture 1126 may align with anaperture in an engine block of the vehicle. By utilizing an existingaperture in an existing component of the engine compartment (e.g., theengine block), it reduces the resources for retrofitting a vehicle withan additional alternator. It should be appreciated that it is within thescope of the present invention that while the top bracket 1110 and themounting post 1120 have been described as separate structures, they maybe a unitary structure as opposed to two separate structures.

As illustrated in FIG. 10, the mounting system 1000 includes a bearingsupport system 1128. The bearing support system 1128 includes a C-shapedsupport member including a bearing (not shown) that rotatably couples tothe shaft 140. As such, the shaft 140 is supported as it experiences aside load that creates a moment of force on the shaft based on thedistal end 1144. The bearing support system 1128 includes a first member1130 that is spaced apart from a second member 1132. The first member1130 extends from a proximal end 1138 to a distal end 1140. The secondmember 1132 extends from a proximal end 1142 to a distal end 1144.

The proximal end 1138 of the first member 1130 includes an aperture thataligns with an aperture in the foot flange 136 of the additionalalternator 102. Additionally, the aperture in the proximal end 1138aligns with an aperture in the one or more mounting flanges in a bottombracket (both of which are obscured from view based on the angle of theperspective), such as one or more mounting flanges 130 of bottom bracket120 of FIG. 1. As such, in an in-mounted configuration, a singlefastener may be used to couple the first member 1130, the foot flange136, and the bottom bracket together.

The proximal end 1142 of the second member 1132 includes an aperturethat aligns with an aperture in the top flange 150 of the additionalalternator 102. Additionally, the aperture in the proximal end 1142aligns with the mounting aperture 1122 of the top bracket 1110. As such,in an in-mounted configuration, a single fastener may be used to couplethe second member 1132, the top flange 150, and the top bracket 110together. As described above, in the illustrated embodiment the mountingaperture 1122 is an elongated slot forming an arc that allows the topflange 150 to travel with respect to the top bracket 1110 so as toadjust the tension in one or more belts. As such, it should beappreciated that the second member 1132 of the bearing support system1128 is capable of traveling along an elongated slot as the additionalalternator 102 moves with respect to the top bracket 1110. This allowsthe bearing support system 1128 to continue to support the shaft 104 asthe additional alternator 102 moves.

In some aspects, the first member 1130 is coupled with the second member1132 via an intermediate member 1134. For example, a distal end of thefirst member 1130 is coupled to the intermediate member 1134. Similarly,a distal end of a second member 1132 is coupled to the intermediatemember 1134. The intermediate member 1134 includes an opening 1136through which the shaft 140 extends. While not shown, a bearing may berotatably coupled to the shaft 140 at or near the distal end 144. Thebearing helps dissipate torsional forces on the shaft 140 as itexperiences a side load due to extending a pulley (e.g., pulley 810)further away from the face of the additional alternator 102. In someaspects, the bearing is a flange bearing that couples to theintermediate member 1134.

As described in greater detail above, the proximal end 142 of the shaft140 is coupled to the shaft 104 of the additional alternator 102. Tosecure the proximal end 142 to the additional alternator 102, the shaft140 may include a flange 1147. In some aspects, the flange 1147 may becoupled to the shaft 140. For example, the flange 1147 may be a bolt-onflange that clamps down on the shaft 140. Alternatively, the flange 1147and the shaft 140 may be a unitary structure.

The flange 1147 includes one or more apertures that align with one ormore apertures of a fan of the additional alternator. A fastener may beused to mount the shaft 140 to the fan of the additional alternator viathe one or more apertures in the flange 1147. It should be appreciatedthat the fan may rattle based on the shaft 140 extending the pulleyfurther from the additional alternator. Mounting the shaft to the fanmay mitigate the rattling of the fan.

In some aspects, the fan of the additional alternator 102 may bemodified to include one or more fan apertures that align with one ormore apertures of the flange 1147. FIGS. 12A-B are each a side elevationviews of a fan plate before and after modification, respectively, inaccordance with some embodiments of the present invention. One or morefan apertures 1210 may be drilled through a fan plate 1200. The one ormore fan apertures 1210 may be positioned concentrically around a centerhole 1212. In some aspects, the one or more fan apertures 1212 may bepositioned at a 90 degree reference angle from a central axis of thecenter hole 1212. As mentioned, the one or more fan apertures 1210 mayreceive a fastener from a flange of a shaft (such as flange 1147).

Additionally or alternatively, the center hole 1212 of the fan plate isenlarged. For instance, a diameter of a center hole 1212 may be enlargedfrom 0.9125 inches to 1.575 inches. It is contemplated that modifyingthe fan plate 1200 may also include removing one or more fan ridges fromthe fan plate.

Referring to both FIGS. 10-11, the mounting system 1000 includes a beltguard 1146 and a first belt guard bracket 1148 and a second belt guardbracket 1152 (shown in FIG. 11). The belt guard 1146 may be a memberthat extends proximate a pulley of the additional alternator 102 to apulley of the existing alternator (e.g., existing alternator 310). Thebelt guard 1146 thus shields the one or more belts driving both theadditional alternator 102 and the existing alternator.

The belt guard 1146 is mounted by one or more brackets. As illustrated,the belt guard 1146 is coupled to the first belt guard bracket 1148 at afirst end 1150 and coupled to the second belt guard bracket 1152 at asecond end 1154. In some aspects, the first belt guard bracket 1148 iscoupled to a mounting bracket 1156. The mounting bracket 1156 may mountto the existing alternator. For instance, the existing alternator may bemounted to a mounting aperture 1158 with a fastener. In someembodiments, the mounting aperture 1158 is an elongated slot forming anarc. The mounting bracket 1156 includes a longer elongated slot than astock mounting bracket. Having a longer elongated slot allows theexisting alternator to travel further with respect to the mountingbracket 1156. This allows the existing alternator to be betterpositioned so as to accommodate the additional alternator 102. While notshown, the mounting bracket 1156 is coupled to an existing component ofthe engine similar to a stock mounting bracket in order to support boththe additional alternator and the belt guard 1146.

Referring to FIG. 11, the additional alternator 102 is supported by oneor more rear support members. For example, the rear of the additionalalternator 102 is supported by a rear support member 1159. The rearsupport member 1159 is coupled to a rear portion 1162 of the additionalalternator 102. For instance, the rear support member 1159 includes amounting aperture 1164 that receives one or more fasteners so as tocouple the rear support member 1159 to the rear portion 1162 of theadditional alternator 102. In some embodiments, the mounting aperture1164 is an elongated slot.

The rear support member 1159 couples to a mounting bracket 1160. In someaspects, the mounting bracket 1160 may be an L-shaped flange bracket.The mounting bracket 1160 includes one or more apertures 1166 (alsoillustrated in in FIG. 10) that allow the mounting bracket 1160 to becoupled to an existing component of the engine compartment. Forinstance, the one or more apertures 1166 may align with existingmounting apertures that already exist in the engine compartment. In someembodiments, the mounting bracket 1160 couples to an engine bracketsupporting an air filter. As such, the mounting bracket 1160 may utilizean existing bracket in the vehicle to secure the rear of the additionalalternator 102 to minimize resources needed to retrofit the vehicle withan additional alternator.

In the illustrated embodiment, the mounting system 1000 also includes amodified air intake system, including a modified air intake pipe 1168and a modified air intake mount assembly. In some aspects, theadditional alternator 102 may be mounted in a position where an existingair intake system would be located. As such, mounting the additionalalternator 102 involves re-routing the existing air intake system. Themodified air intake system may include one or more sections of airintake piping that accommodates the additional alternator 102.

From the foregoing it will be seen that this invention is one welladapted to attain all ends and objects hereinabove set forth togetherwith the other advantages which are obvious and which are inherent tothe method and apparatus. It will be understood that certain featuresand subcombinations are of utility and may be employed without referenceto other features and subcombinations. This is contemplated by and iswithin the scope of the invention.

Further, the above detailed description described the illustratedembodiment. Alternate embodiments with modifications to various featureexist and are contemplated that still fall within the scope of thepresent invention.

Since many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is to be understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illustrative of applications of the principles of thisinvention, and not in a limiting sense.

What is claimed is:
 1. A mounting system for mounting an additionalalternator in combination with an existing alternator and using analternator mount supporting an existing alternator, the alternator mounthaving a first member with a first aperture, the mounting systemcomprising: a top bracket comprising a first bracket aperture, the firstbracket aperture configured to align with a top flange aperture in a topflange of the additional alternator; and a bottom bracket comprising oneor more mounting flanges and a second bracket aperture that aligns withthe first aperture of the first member of the alternator mount, whereinthe one or more mounting flanges has a flange aperture that aligns witha foot flange aperture in a foot flange of the additional alternator. 2.The mounting system of claim 1, wherein the mounting system positionsthe additional alternator in a mounted position such that the additionalalternator is alongside the existing alternator.
 3. The mounting systemof claim 1 further comprising a protective guard configured to shieldthe additional alternator.
 4. The mounting system of claim 1 furthercomprising a protective guard configured to shield a pulley of theadditional alternator, a belt driving the additional alternator, or boththe pulley and the belt.
 5. The mounting system of claim 1 furthercomprising a belt guard configured to shield one or more belts drivingthe additional alternator, the existing alternator, or both theadditional alternator and the existing alternator.
 6. The mountingsystem of claim 1, wherein the top bracket further comprises a first topwall, wherein the first bracket aperture extends through the first topwall.
 7. The mounting system of claim 1, wherein the bottom bracketfurther comprises a first bottom wall, wherein the second bracketaperture extends through the first bottom wall.
 8. The mounting systemof claim 1 further a comprising a shaft adjacent to and extendingperpendicular to a front face of the additional alternator, wherein theshaft comprises a first end and a second end, wherein the first end isconfigured to couple to the additional alternator and the second end isconfigured to attach to a first pulley.
 9. The mounting system of claim8, wherein the first pulley aligns with a second pulley of the existingalternator.
 10. The mounting system of claim 8, wherein the first pulleyand the second pulley are driven by a single belt.
 11. A method formounting an additional alternator to a vehicle having an existingalternator, the method comprising: securing a top bracket to an existingcomponent of an engine of the vehicle by aligning a first bracketaperture of the top bracket with a first aperture in a first member ofthe existing component of the engine; securing a bottom bracket to analternator mount supporting the existing alternator by aligning a secondbracket aperture of the bottom bracket with a second aperture in asecond member of the alternator mount; and mounting the additionalalternator alongside the existing alternator utilizing the top andbottom brackets, wherein the additional alternator is mounted such that:an aperture in a top alternator flange of the additional alternator isaligned with a mounting aperture of the top bracket, and an aperture ina foot alternator flange of the additional alternator is aligned with amounting aperture of the bottom bracket.
 12. The method of claim 11,wherein the additional alternator is mounted such that the additionalalternator is offset laterally and longitudinally from the existingalternator.
 13. The method of claim 12 further comprising mounting abelt guard to the alternator mount.
 14. The method of claim 13, whereinthe belt guard is mounted such that the belt guard extends proximate apulley of the additional alternator.
 15. The method of claim 13, whereinthe belt guard is configured to shield one or more belts driving theadditional alternator, the existing alternator, or both the additionalalternator and the existing alternator.
 16. The method of claim 11,wherein the top bracket comprises a first top wall, wherein the firstbracket aperture extends through the first top wall.
 17. The method ofclaim 11, wherein the bottom bracket comprises first bottom wall,wherein the second bracket aperture extends through the first bottomwall.
 18. A mounting system for mounting an additional alternator incombination with an existing alternator and using an alternator mountsupporting an existing alternator, the alternator mount having a firstmember with a first aperture, the mounting system comprising: a top wallcomprising a first bracket aperture configured to align with a topflange aperture in a top flange of the additional alternator; a bottomwall comprising a second bracket aperture that aligns with the firstaperture of the first member of the alternator mount; and one or moremounting flanges comprising a flange aperture that aligns with a footflange aperture in a foot flange of the additional alternator.
 19. Themounting system of claim 18 further comprising a belt guard configuredto shield one or more belts driving the additional alternator, theexisting alternator, or both the additional alternator and the existingalternator.
 20. The mounting system of claim 19, wherein the belt guardcomprises a first belt guard bracket that is coupled to a mountingbracket of the alternator mount.